CN102076303B - Comprise the elastic composite of low-intensity and lightweight nonwoven facings - Google Patents

Comprise the elastic composite of low-intensity and lightweight nonwoven facings Download PDF

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Publication number
CN102076303B
CN102076303B CN200980125530.6A CN200980125530A CN102076303B CN 102076303 B CN102076303 B CN 102076303B CN 200980125530 A CN200980125530 A CN 200980125530A CN 102076303 B CN102076303 B CN 102076303B
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China
Prior art keywords
elastic
facings
composite
styrene
nonwoven facings
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CN200980125530.6A
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Chinese (zh)
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CN102076303A (en
Inventor
H·M·韦尔奇
J·奥斯丁
L·萨纳波利尔
J·A·斯奎拉
W-C·恩治
B·D·海内斯
O·P·托马斯
I·V·楚玛彻
C·拉斯里
S·C·梅尔
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Kimberly Clark Worldwide Inc
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Kimberly Clark Worldwide Inc
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/681—Spun-bonded nonwoven fabric

Abstract

Provide a kind of elastic composite formed by lightweight nonwoven facings, described nonwoven facings has low-intensity in transverse machine (" CD ").Control the special parameter in the material that adopts in composite and forming method by selectivity, the present inventor finds, and such low-intensity and the facings of lightweight can be laminated to elastica easily, and can not destroy their integrity significantly.Such as, in one embodiment, the knot that elastica can have multilamellar is made, and comprises the elastomeric elastic layer adjacent with strengthened thermoplastic layer.The component of polymer of thermoplastic layer and thickness can be selected to give the extra intensity of film and integrity usually.Similarly, the component of polymer of elastic layer also can be selected, and has enough viscosity to adhere to facings to make film.Under specific circumstances, can it is desirable for and layer is positioned between two elastic layers, make intensity enhancing layer substantially can not contact nonwoven facings.Like this, strengthened layer can avoid substantial damage during laminating technology.

Description

Comprise the elastic composite of low-intensity and lightweight nonwoven facings
background of invention
Elastic composite often closes and joins in goods (such as diaper, training pants, medicated clothing etc.) to improve the ability of its body contour of fitting better.Such as, elastic composite can be formed by elastica and nonwoven web facings.Nonwoven web facings can be bonded to by heat and pressure (such as stack) elastica being in extended state, and during with convenient film retraction, nonwoven web facings can be assembled and be formed " pleat " between the position that it is bonded to film.The elastic composite obtained may spread to the degree that pleat allows elastica to extend.In order to reduce costs, it is desirable to form such composite by the nonwoven web facings of lower basic weight and intensity.Unfortunately, low intensive facings is difficult to manufacture due to its shortage durability and integrity.Such as, the heat that applies of traditional stack and pressure can destroy the integrity of facings significantly.In addition, the facings that basic weight is larger needs durability usually due to the gathering of material during lamination.
Therefore, the elastic composite that current needs are formed by lightweight and low intensive nonwoven web lining cloth, and also in effective use of various application, there is enough durability.
invention summary
According to embodiment of the present invention, disclose elastic composite, this composite comprises elastica and adjacent with the position of elastica and coarctate with layers of elastomeric film nonwoven web facings.The basic weight of this nonwoven web facings is about 45 grams/m or less, and the peak load in transverse machine is about 350 gram forces/inch or less.In addition, the peak elongation of this composite in a machine direction, in transverse machine or in this both direction is about 75% or larger.
According to another embodiment of the invention, disclose the method forming elastic composite.The method comprises directly to be extruded elastic composition to form elastica on the surface of nonwoven web facings, and makes film combine to form composite with nonwoven web facings.The basic weight of this nonwoven web facings is about 45 grams/m or less, and peak load is in the cross machine direction about 350 gram forces/inch or less.In addition, the peak elongation of this composite in a machine direction, in transverse machine or this both direction is about 75% or larger.
Next further feature of the present invention and aspect will be described in detail.
brief description of drawings
The remaining part of this description more specifically illustrates disclosure of the present invention (comprising best mode) complete to those skilled in the art and in the cards with reference to accompanying drawing, wherein:
Fig. 1 diagrammatically illustrates the method forming composite according to an embodiment of the invention;
Fig. 2 diagrammatically illustrates the method forming composite according to another embodiment of the invention;
Fig. 3 is the perspective view of the personal care product that can make according to one embodiment of the invention;
Fig. 4 is the perspective view for the grooved roller in one embodiment of the invention;
Fig. 5 illustrates the cross-sectional view of the joint in Fig. 4 between two grooved rollers.
Fig. 6 is the SEM microphotograph (350X) of the composite that embodiment 1 is formed; And
Fig. 7 is another SEM microphotograph (1100X) of the composite that embodiment 1 is formed.
This description and Reference numeral reusable in accompanying drawing are intended to represent identical or similar feature or element in the present invention.
the detailed description of representative embodiment
definition
As used herein, term " nonwoven web " refers to the fibre web with ultimate fibre or silk structure, and described ultimate fibre or silk mutually do not insert in certifiable mode like that with braided fabric.The example being applicable to adhesive-bonded fabric or fibre web includes, but not limited to melt spray fibre web, spunbond fibre web, bonded carded web, air-laid webs, same to formed web, water thorn winding fibre web etc.
As used herein, term " melt-blown " fibre web or facings typically refer to the nonwoven web formed by the following method: the thermoplastic of melting is extruded through multiple die capillaries that is meticulous, that be generally annular as fused fiber, enter the high speed gas of convergence (such as, in empty stream, the high velocity air of described convergence can make the fiber of the thermoplastic of melting attenuate to reduce their diameter, can be reduced to microfiber diameter; Subsequently, meltblown fibers is carried by high velocity air and is deposited on collection on the surface, to form the fibre web of the meltblown fibers of random dispersion.Such method is such as the people such as Butinthe 3rd, 849, No. 241 United States Patent (USP)s, at this, its full content is incorporated herein by reference for all objects.
As used herein, term " spunbond " fibre web or facings typically refer to the nonwoven web of the fiber containing minor diameter, basic continous.Described fiber by by the thermoplastic of melting from multiple carefully, the spinneret capillary pipe that is generally annular extrudes, then the diameter extruding silk is reduced rapidly by such as emanate stretching (eductivedrawing) and/or other spunbond mechanism known and is formed.The production of sticky spun web such as exists the people such as Appelthe 4th, 340, No. 563 United States Patent (USP)s, the people such as Dorschnerthe 3rd, 692, No. 618 United States Patent (USP)s, the people such as Matsukithe 3rd, 802, No. 817 United States Patent (USP)s, kinneythe 3rd, 338, No. 992 and the 3rd, 341, No. 394 United States Patent (USP)s, hartmanthe 3rd, 502, No. 763 United States Patent (USP)s, levythe 3rd, 502, No. 538 United States Patent (USP)s, the people such as Dobothe 3rd, 542, No. 615 United States Patent (USP)s and the people such as Pikethe 5th, 382, No. 400 United States Patent (USP)s in have describe and illustrate, at this, its full content is incorporated herein by reference for all objects.When deposited onto a collecting surface, spunbond silk is not sticky usually.Usually, the diameter of spun-bonded fibre can be about 10 to about 20 microns.
As used herein, term " machine direction " or " MD " are commonly referred to as the direction producing material.Term " transverse machine " or " CD " refer to the direction perpendicular with machine direction.
As used herein, the mensuration of term " lagged value " records by making sample retraction (" unloading load ") after first drawn samples (" load ").The loss of energy during lagged value is this cyclic load.
describe in detail
Now with detailed reference to various embodiments of the present invention, one or more embodiment of the present invention is described below.Each embodiment provides all by way of explanation of the invention, and unrestricted the present invention.In fact, will be evident for a person skilled in the art that when not deviating from scope of the present invention or spirit, various modifications and variations can be made to the present invention.Such as, the feature that the part as an embodiment illustrates or describes, can be used in another embodiment and produce another embodiment.Therefore, the present invention is intended to contain modifications and variations such within claims and equivalency range thereof.
The present invention generally relates to the elastic composite formed by lightweight nonwoven facings, this lightweight nonwoven facings has low-intensity in transverse machine (" CD ").Controlled some parameter and the forming process of the material used in composite by selectivity, the present inventor finds, and the facings of such low-intensity and lightweight easily can be laminated to elastica and their integrity of not obvious destruction.Such as, in one embodiment, elastica can have multiple structure, and this multiple structure comprises the elastomeric resilient layer of the thermoplastic layer of the contiguous strength reinforcing in position.The polymer content of thermoplastic layer and thickness are selected through routine, thus give the extra intensity of film and integrity.Similarly, the polymer content of elastica also can be selected to make film have enough viscosity for attachment to facings.In some cases, it is desirable to arrange layer between two elastic layers, make intensity enhancement Layer substantially not contact nonwoven facings.In this way, intensity enhancement Layer can avoid the substantial damage in lamination process
In this respect, multiple embodiments of the present invention will be described in further detail now.
I. nonwoven facings
As mentioned above, the nonwoven facings of ground floor laminate is generally lightweight, and has low-intensity in transverse machine (" CD "), and this is by the flexibility improving composite and also significantly lower in its manufacturing cost.More specifically, basic weight can be about 45 grams/m or less, is about 1 to about 30 grams/m in some embodiments, is about 2 to about 20 grams/m in some embodiments.Similarly, nonwoven web facings peak load is in the cross machine direction about 350 gram forces/inch (width) or less, in some embodiments, for about 300 gram forces/inch or less, in some embodiments, for about 50 to about 300 gram forces/inch, in some embodiments, for about 60 to about 250 gram forces/inch, and in some embodiments, for about 75 to about 200 gram forces/inch.If desired, nonwoven facings has low-intensity in machine direction (" MD "), such as, peak load is in a machine direction about 3000 gram forces/inch (width) or less, in some embodiments, is about 2500 gram forces/inch or less, in some embodiments, for about 50 to about 2000 gram forces/inch, and in some embodiments, for about 100 to about 1500 gram forces/inch.
Nonwoven facings can be formed by multiple known method, such as meltblown, spun-bond process, combing method, wet-laid processes, air laid, with the method for forming etc.In a specific embodiment, such as, nonwoven facings is the melt-blown facings comprising " microfibre ", the average-size of wherein said microfibre is about 15 microns or less, in some embodiments, for about 0.01 to about 10 microns, and in some embodiments, be about 0.1 to about 5 microns.
Regardless of the mode that it is formed, nonwoven facings is formed by the polymer with relatively high vicat softening temperature (ASTMD-1525) usually, such as about 100 DEG C to about 300 DEG C, in some embodiments, for about 120 DEG C to about 250 DEG C, and in some embodiments, be about 130 DEG C to about 200 DEG C.Exemplary high softening-point polymer for the formation of nonwoven facings can include, but not limited to such as, and polyolefin, as polyethylene, polypropylene, polybutene etc.; Politef; Polyester, as polyethylene terephthalate etc.; Polyvinyl acetate; Polyvinyl chloride-acetate; Polyvinyl butyral resin; Acrylic resin, as polyacrylate, polymethyl acrylate, polymethyl methacrylate etc.; Polyamide, as nylon; Polrvinyl chloride; Poly-inclined vinylidene chloride; Polystyrene; Polyvinyl alcohol; Polyurethane; Polylactic acid; Their polymer; Their blend etc.It should be noted that polymer can also comprise other additive, as processing aid or give the treatability compositions of the fiber character of wishing, the solvent of surplus, pigment or colorant etc.
One pack system and/or multicomponent fibre can be used to form nonwoven facings.Homofil usually to be extruded through single extruder by the blend of a kind of polymer or polymer and is formed.Multicomponent fibre extrudes formation by two or more polymer (such as, bicomponent fibre) separated extruder usually.Described polymer is disposed in the zones of different of substantial constant location on fiber cross section.Described component can be arranged with the configuration of any hope, as core-skin type, parallel type, pie type (pie), marine island, three island, buphthalmos or other configuration known in the art etc.The distinct methods forming multicomponent fibre exists the people such as Taniguchithe 4th, 789, No. 592 United States Patent (USP)s, the people such as Strackthe 5th, 336, No. 552 United States Patent (USP)s, the people such as Kanekothe 5th, 108, No. 820 United States Patent (USP)s, the people such as Kruegethe 4th, 795, No. 668 United States Patent (USP)s, the people such as Pikethe 5th, 382, No. 400 United States Patent (USP)s, the people such as Strackthe 5th, 336, No. 552 United States Patent (USP)s, the people such as Marmonthe 6th, 200, No. 669 United States Patent (USP)s in have description, at this, its full content is incorporated herein by reference for all objects.Having various erose multicomponent fibre also can being formed such as described by following United States Patent (USP): the people such as Hoglethe 5th, 277, No. 976 United States Patent (USP)s, hillsthe 5th, 162, No. 074 United States Patent (USP), hillsthe 5th, 466, No. 410 United States Patent (USP)s, the people such as Largmanthe 5th, 069, No. 970 United States Patent (USP)s, the people such as Largmanthe 5th, 057, No. 368 United States Patent (USP)s in, at this, its full content is incorporated herein by reference for all objects.
Denier for the formation of the hope of the fiber of nonwoven facings can be different according to required purposes.Usually, the monofilament Denier (that is, the unit of line density equals the quality (in gram) of every 9000 meters of fibers) of the fiber of formation is less than about 6, in some embodiments, for being less than about 3, and in some embodiments, be about 0.5 to about 3.
Although do not require, nonwoven facings can utilize any traditional technology optionally to combine, as utilize binding agent or idiopathic (as melting and/or when without the need to applying external binder the bonds itself of fiber).The spontaneous combination technology be applicable to can comprise ultrasound wave combination, thermal, hot blast combination, calendering combination etc.The temperature and pressure needed can change according to many factors, includes but not limited to, the character of the character of combination of patterns district, polymer, the character of fiber and nonwoven web.Such as, the roll gap of facings by being formed between two rollers, these two rollers do not have pattern usually, are namely flat.Like this, only need apply a small amount of pressure on material they are combined lightly.Be not limited by theory, the present inventor thinks that the material combined gently like this can keep higher extensibility and thus add elasticity and the extensibility of the composite obtained.Such as, the pressure of roll gap is about 0.1 to about 20 pounds/linear inch, in some embodiments, for about 1 to about 15 pounds/linear inch, and in some embodiments, for about 2 to about 10 pounds/linear inch.Similarly, the surface temperature of one or more roller is about 15 DEG C to about 60 DEG C, in some embodiments, is about 20 DEG C to about 50 DEG C, and in some embodiments, is about 25 DEG C to about 40 DEG C.
Before carrying out lamination with film of the present invention, also can extend nonwoven facings in machine direction and/or in the cross machine direction.The elongation technology be applicable to comprises constriction, tentering, grooved roller extension etc.Such as, can be as mormanthe 5th, 336, No. 545, the 5th, 226, No. 992, the 4th, 981, No. 747 and the 4th, 965, No. 122 United States Patent (USP)s and the people such as Mormanthe method constriction facings described in No. 2004/0121687th, U.S. Patent application.Alternatively, with rete pressure before, nonwoven facings keeps relatively non-extensible at least one direction.In such embodiments, nonwoven facings can optionally extend in one or more directions, subsequently with rete pressure.Facings also can be passed through other known procedure of processing, such as perforation, heat treatment etc.
II. elastica
Elastica of the present invention is formed by the elastomer polymer of (that is, the thermoplasticity) of one or more melt-processable.Any one of various thermoplastic elastomer polymer all can be used in the present invention, as elastomeric polyester, elastomer polyurethane, elastomer polyamide, elastomer copolymer, elastomeric polyolefin etc.In one embodiment, such as, can use basic is unbodied block copolymer, and this block polymer comprises the block of mono alkenyl arene and saturated conjugated diene.Because such block copolymer has elasticity and the viscosity of height, be thus specially adapted to the present invention, be bonded to the ability of nonwoven facings in order to reinforcing membrane.
Monoalkenyl arene blocks can comprise styrene and analog thereof and homologue, as o-methyl styrene, p-methylstyrene, p-tert-butylstyrene, 1, and 3 dimethyl styrene p-methylstyrenes etc.; And other mono-alkenyl polycyclc aromatic compound, as vinyl naphthalene, vinyl anthracene etc.Preferred mono alkenyl arene is styrene and p-methylstyrene.Conjugated diene block can comprise the copolymer of the homopolymer of conjugate diene monomer, the copolymer of two or more conjugated dienes and one or more diene and another kind of monomer, and wherein block is mainly conjugated diene unit.Preferably, conjugated diene comprises 4 to 8 carbon atoms, as 1,3-butadiene (butadiene), 2-methyl isophthalic acid, and 3 butadiene, isoprene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene (pentadiene), 1,3-hexadiene etc.The amount of mono alkenyl arene (as polystyrene) block can change, but usually account for about 8 % by weight of copolymer to about 55 % by weight, in some embodiments, account for about 10 % by weight to about 35 % by weight, and in some embodiments, account for about 25 % by weight to about 35 % by weight.It is about 5 that the block copolymer be applicable to can comprise number-average molecular weight, and the mono alkenyl arene end-blocks of 000 to about 35,000 and number-average molecular weight are about 20, the saturated conjugated diene mid-block of 000 to about 170,000.The total number average molecular weight of block polymer is about 30,000 to about 250,000.
Particularly suitable thermoplastic elastomer copolymer can obtain from the KratonPolymersLLC of Houston, Texas, and trade mark is called KRATON kRATON polymer comprises Styrene-diene block copolymer, as styrene-butadiene, styrene-isoprene, s-B-S and styrene-isoprene-phenylethene.KRATON polymer also comprises, the styrene-olefm block copolymer formed through selective hydration effect by Styrene-diene block copolymer.The example of such styrene-olefm block copolymer comprises, styrene-(Ethylene/Butylene), styrene-(ethylene-propylene), styrene-(Ethylene/Butylene)-styrene, styrene-(ethylene-propylene)-styrene, styrene-(Ethylene/Butylene)-styrene-(Ethylene/Butylene), styrene-(ethylene-propylene)-styrene-(ethylene-propylene) and styrene-ethylene-(ethylene-propylene)-styrene.These block copolymers all have molecular structure that is linear, radial or star.Concrete KRATON block copolymer comprises, and those press trade (brand) name G1652, G1657, G1730, MD6673 and MD6973 product on sale.At the the 4th, 663, No. 220, the 4th, 323, No. 534, the 4th, 834, No. 738, the 5th, 093, No. 422 and the 5th, describe various applicable styrene block copolymer in 304, No. 599 United States Patent (USP)s, at this for all objects by these references cited therein as a reference.Other commercially available block copolymer comprises, and can obtain from the KurarayCompany of Japanese Okayama, Ltd., Trademark design is SEPTON s-EP-S elastomer copolymer.Other copolymer be applicable to comprises and can obtain from the DexcoPolymers of Houston, Texas, and Trademark design is VECTOR s-I-S and S-B-S elastomer copolymer.Be applicable to polymer also just like the people such as Taylorthe 5th, 332, No. 613 United States Patent (USP)s in the A-B-A-B Tetrablock copolymer that describes, be introduced into as a reference for all objects at this.The example of such Tetrablock copolymer is styrene-poly-(ethylene-propylene)-styrene-poly-(ethylene-propylene) (" S-EP-S-EP ") block copolymer.
Certainly, other thermoplastic elastomer polymer also can be used to form film, can separately or be combined with block copolymer.Also can use the semicrystalline polyolefins such as having and maybe can show fundamental rule structure.Exemplary semicrystalline polyolefin comprises polyethylene, polypropylene, its blend and copolymer.In a specific embodiment, the polyethylene of use is the copolymer of ethylene and alpha-olefin, and alpha-olefin is as C 3-C 20alpha-olefin or C 3-C 12alpha-olefin.The alpha-olefin be applicable to can be (such as, one or more C of straight chain or side chain 1-C 3alkyl branches or aromatic yl group).Concrete example comprises 1-butylene; 3-methyl-1-butene; 3,3-dimethyl-1-butylene; 1-amylene; There is the 1-amylene of one or more methyl, ethyl or propyl substituent; There is the 1-hexene of one or more methyl, ethyl or propyl substituent; There is the 1-heptene of one or more methyl, ethyl or propyl substituent; There is the 1-octene of one or more methyl, ethyl or propyl substituent; There is the 1-nonene of one or more methyl, ethyl or propyl substituent; The 1-decene that ethyl, methyl or dimethyl replace; 1-dodecylene; And styrene.The alpha-olefin comonomer of special hope is 1-butylene, 1-hexene and 1-octene.In such copolymer, the content of ethylene is about 60 % by mole to about 99 % by mole, in some embodiments, is about 80 % by mole to about 98.5 % by mole, and in some embodiments, is about 87 % by mole to about 97.5 % by mole.Similarly, the content of alpha-olefin is about 1 % by mole to about 40 % by mole, in some embodiments, is about 1.5 % by mole to about 15 % by mole, and in some embodiments, is about 2.5 % by mole to about 13 % by mole.
Particularly suitable polyethylene and ethylene copolymers is those " linearly " or " being linear substantially ".Predicate " being linear substantially " refers to except the short-chain branches adding comonomer, and ethene polymers also comprises the long chain branch as polymer backbone." branch's long-chain " refers to the chain that length is at least 6 carbon.Each long chain branch can have the comonomer distribution identical with polymer backbone, and identical with the length of the polymer backbone of its combination.Preferred is that linear polymer 0.01 long chain branch/1000 carbon to 1 long chain branch/1000 carbon replace substantially, and in some embodiments, replaces with 0.05 long chain branch/1000 carbon to 1 long chain branch/1000 carbon.Formed with term " being linear substantially " and contrast, term " linearly " refers to that polymer lacks can survey or evincible long chain branch.That is, polymer replaces with being on average less than 0.01 long chain branch/1000 carbon.
The density of linear ethylene/alpha olefin copolymer is the length of alpha-olefin and the function of content.That is, the length of alpha-olefin is larger and the content of alpha-olefin is larger, and the density of copolymer is less.Although optional, linear polyethylene " plastic body " is special hope, because the content of alpha-olefin short chain branch composition makes ethylene copolymer show plasticity and elastomeric characteristic simultaneously, i.e. " plastic body ".Because will reduce degree of crystallinity and density with the polymerization of alpha-olefin comonomer, the plastic body thus obtained will have the density less than polythene thermoplastic polymer (i.e. LLDPE) usually, but close to and/or exceed elastomeric density.Such as, the density of polyethylene plastomers is 0.91 gram/cc of (g/cm 3) or less, in some embodiments, be 0.85-0.88g/cm 3, and in some embodiments, be 0.85g/cm 3-0.87g/cm 3.Although the density of plastic body is close to elastomeric density, plastic body shows higher degree of crystallinity, relatively sticky usually, and can be formed non-caked and relatively be easy to the bead that flows.
For preferred polyethylene of the present invention be can obtain from the Exxon Mobil chemical company of Houston, Texas, commodity are called EXACT tMthe copolymer plastic body based on vinyl.Other polyethylene plastomers be applicable to can obtain from the Dow Chemical of Midland, Michigan, and commodity are called ENGAGE tMand AFFINITY tMcomposition.Also have other the ethene polymers be applicable to can obtain from Dow Chemical, commodity are called DOWLEX tMand ATTANE (LLDPE) tM(ULDPE).? the people such as Ewenthe 4th, 937, No. 299 United States Patent (USP)s, the people such as Tsutsuithe 5th, 218, No. 071 United States Patent (USP), the people such as Laithe 5th, 272, No. 236 United States Patent (USP)s and the people such as Laithe 5th, 278, No. 272 United States Patent (USP)s in describe other be applicable to ethene polymers, these documents are incorporated herein by reference for all objects at this.
Certainly, the present invention is not limited to use ethene polymers.Such as, propylene plastic body is also applicable in film.The plastic propene's polymer be applicable to can comprise, the copolymer of such as propylene or terpolymer, comprises propylene and alpha-olefin (as C 3-C 20) copolymer, described alpha-olefin is as ethylene, 1-butylene, 2-butylene, various pentene isomers, 1-hexene, 1-octene, 1-nonene, 1-decene, 1-endecatylene, 1-dodecylene, 4-methyl-1-pentene, 4-methyl isophthalic acid-hexene, 5-methyl isophthalic acid-hexene, VCH, styrene etc.The content of the comonomer of acrylic polymers is about 35 % by weight or less.In some embodiments, be about 1 % by weight to about 20 % by weight, and in some embodiments, be about 2 % by weight to about 10 % by weight.Preferably, the density of polypropylene (as propylene/alpha-olefins copolymer) can be 0.91 gram/cc of (g/cm 3) or less, in some embodiments, be 0.85-0.88g/cm 3, and in some embodiments, be 0.85g/cm 3-0.87g/cm 3.The acrylic polymers be applicable to can be what to be purchased from the Exxon Mobil chemical company of Houston, Texas, and commodity are called VISTAMAXX tM, purchased from the FINA of the AtofinaChemicals of Feluy, Belgium tM(as 8573), TAFMER purchased from Mitsui petrochemical industry tMwith the VERSIFY of the Dow Chemical purchased from Midland, Michigan tM.? the people such as Dattathe 6th, 500, No. 563 United States Patent (USP)s, the people such as Yangthe 5th, 539, No. 056 United States Patent (USP) and the people such as Resconithe 5th, 596, No. 052 United States Patent (USP) in describe other example of applicable acrylic polymers, these entirety are incorporated herein by reference for all objects at this.
Any one in many known methods all can be used for forming hemicrystalline polyolefin.Such as, olefin polymer can utilize free radical or complex catalyst (as Ziegler-Natta) to obtain.Preferably, olefin polymer is by unit point complex catalyst, and such as metalloscene catalyst is formed.Such catalyst system prepares ethylene copolymer, and wherein comonomer will be randomly dispersed in strand, and is evenly distributed between different molecular weight fractions.Such as, exist mcAlpin deng peoplethe 5th, 571, No. 619 United States Patent (USP)s, the people such as Davisthe 5th, 322, No. 728 United States Patent (USP)s, the people such as Obiieskithe 5th, 472, No. 775 United States Patent (USP)s, the people such as Laithe 5th, 272, No. 236 United States Patent (USP)s and the people such as Wheatthe 6th, 090, No. 325 United States Patent (USP)s in describe the polyolefin of metallocene catalyst, these entirety are incorporated herein by reference for all objects at this.The example of metalloscene catalyst comprises, two (normal-butyl cyclopentadienyl) titanium chloride, two (normal-butyl cyclopentadienyl) zirconium dichloride, two (cyclopentadienyl) Scium chloride (Sc4Cl12), two (indenyl) zirconium dichloride, two (methyl cyclopentadienyl) titanium chloride, two (methyl cyclopentadienyl) zirconium dichloride, cobaltocene, cyclopentadienyl titanous chloride., ferrocene, dichloro hafnocene, isopropyl (cyclopentadienyl-1-fluorenyl) zirconium dichloride, the luxuriant molybdenum of dichloro two, dicyclopentadienyl nickel, the luxuriant niobium of dichloro two, ruthenocene, cyclopentadienyl titanium dichloride, hydrogen chlorine zirconocene, bis cyclopentadienyl zirconium dichloride etc.The polymer prepared with metalloscene catalyst has narrower molecular weight distribution usually.Such as, the polydispersity numerical value (M of the polymer of metallocene catalyst w/ M n) below 4, determine short chain distribution and determine isotacticity.
Although the melt flow index of semicrystalline polyolefins (MI) generally can change, but about 0.1 gram/10 minutes that normally record at 190 DEG C to about 100 grams/10 minutes, in some embodiments, for about 0.5 gram/10 minutes to about 30 grams/10 minutes, and in some embodiments, be about 1 gram/10 minutes to about 10 grams/10 minutes.Melt flow index is at 190 DEG C, when being subject to the pressure of 5000 gram forces of 10 minutes, by the weight (gram) of polymer recorded according to ASTM detection method D1238-E time squeezing rheometer aperture (0.0825 inch diameter).
Certainly, except elastomer polymer, as long as inelastic thermoplastic polymer can not adversely affect the elasticity of composite, generally just also it can be used.Such as, thermoplastic compounds can comprise other polyolefin (as polypropylene, polyethylene etc.).In one embodiment, thermoplastic compounds can comprise extra acrylic polymers, as the copolymer of homo-polypropylene or propylene.Extra acrylic polymers can be, such as, by substantially being formed for isotactic polypropylene homopolymer or the copolymer containing other monomer (i.e. at least about propylene of 90 % by weight) being equal to or less than about 10 % by weight.Polyacrylic existence form like this can be grafting, random or block copolymer, and can mainly crystalline solid, and its peak melting point is about more than 110 DEG C, in some embodiments, for about more than 115 DEG C, and in some embodiments, be about more than 130 DEG C.? the people such as Dattathe 6th, 992, No. 159 United States Patent (USP)s in describe so extra polyacrylic example, the document is incorporated herein by reference in full for all objects at this.
Elastica also comprises the known component of other prior art.In one embodiment, such as, elastica comprises filler.Filler is the material of graininess or other form, can be added in the blend that membrane polymer extrudes, and can not chemically affect the film extruded, but can be evenly dispersed in film.Filler can use for various purposes, comprises the opacity of reinforcing membrane and/or breathability (that is, permeable gas and impermeable liquid substantially).Such as, filled film can make breathable by extending, and this will cause polymer to depart from filler and produce the passage of micropore.Such as the people such as McCormackthe 5th, 997, No. 981, the 6th, 015, No. 764 and the 6th, 111, No. 163 United States Patent (USP)s; the people such as Mormanthe 5th, 932, No. 497 and taylor deng peoplethe 6th, 461, No. 457 in describe breathable microcellular elastomeric film, these entirety are incorporated herein by reference for all objects at this.The example of the filler be applicable to comprises, but be not limited to, calcium carbonate, various clay, silicon dioxide, aluminium oxide, brium carbonate, sodium carbonate, magnesium carbonate, Talcum, barium sulfate, magnesium sulfate, aluminum sulfate, titanium dioxide, zeolite, cellulose-type powders, Kaolin, Muscovitum, carbon, calcium oxide, magnesium oxide, aluminium hydroxide, slurry powder, wood powder, cellulosic derivant, chitin and chitin derivative.In some cases, in film, the content of filler is about 25 % by weight of film to about 75 % by weight, in some embodiments, is about 30 % by weight to about 70 % by weight, and in some embodiments, is about 40 % by weight to about 60 % by weight.
Also other additive can be added, as melt stability agent, crosslinking catalyst, pro-rad additive, processing stabilizers, heat stabilizer, light stabilizer, antioxidant, heat aging stabilizers, brightening agent, anti-caking agent, binding agent, adhesive, viscosity modifier etc. in film.The example of the adhesive resin be applicable to comprises, such as hydrogenated hydrocarbon resins.The example of such hydrogenated hydrocarbon resins is REGALREZ tMhydrocarbon resin, can obtain from EastmanChemical.Other adhesive can obtain from Exxon Mobil, and commodity are called ESCOREZ tM.Also viscosity modifier can be used, as Tissuemat E (such as, derives from the EPOLENE of EastmanChemical tMc-10).Phosphites stabilizers (such as, can derive from Terrytown, the IRGAFOS of the CibaSpecialtyChemicals of NewYork and derive from Dover, the DOVERPHOS of the DoverChemicalCorp. of Ohio) is exemplary melt stability agent.In addition, hindered amine stabilizer (as derived from the CHIMASSORB of CibaSpecialtyChemicals) is exemplary light and heat stabilizing agent.In addition, hindered phenol is commonly used for antioxidant in the preparation process of film.Some hindered phenols be applicable to comprise purchased from CibaSpecialtyChemicals, trade (brand) name " Irganox " those, as Irganox 1076,1010 or E201.In addition, film bonding agent can also be added to film to promote that film and additional materials (as nonwoven web) combine.Usually, such additive (as adhesive, antioxidant, stabilizing agent etc.) content in film is respectively about 0.001 % by weight to about 25 % by weight, in some embodiments, for about 0.005 % by weight to about 20 % by weight, and be in some embodiments, 0.01 % by weight to about 15 % by weight.
Elastica of the present invention is single or multiple lift.Multilayer film obtains by coextrusion or other traditional demixing technology any.When deployed, multilayer film comprises at least one thermoplastic layer and at least one elastic layer usually.Thermoplastic layer is used for giving intensity and the integrity of the composite obtained, and elastic layer by its elasticity of imparting and enough adhesivities to adhere to nonwoven facings.In a specific embodiment of the present invention, film comprises at least one thermoplastic layer between at least two elastic layers.Like this, thermoplastic layer does not contact nonwoven facings substantially, and therefore can avoid the substantial damage during lamination.In such embodiments, one or more elastic layer is formed by elastic composition usually, as above, to give the DE that film is wished.In order to give the elastic property that film is wished, elastomer occupies about 55 % by weight of polymer content in the elastic composition forming elastic layer or more usually, in some embodiments, for about 60 % by weight or more, and be in some embodiments, about 65 % by weight to 100 % by weight.In fact, in certain embodiments, elastic layer is not usually containing stiff polymer.Such as, such non-elastic polymer can account for about 15 % by weight or less of the polymer content of elastic composition, in some embodiments, is about 10 % by weight or less, and in some embodiments, is about 5 % by weight or less.
Although thermoplastic layer has certain DE, the thermoplastic compounds that such layer is weaker than elastic layer by elasticity is usually formed, to guarantee that film strength is enough to greatly.Such as, one or more elastic layer can primarily of being substantially amorphous elastomeric body (as styrene-olefin copolymer) formation, and one or more thermoplastic layer can be formed by polyolefin plastomers (as single site catalysed ethylene or propylene copolymer), this all has a detailed description hereinbefore.Polyolefin although it is so has some elasticity, but its elasticity is weaker than basic is usually amorphous elastomeric elasticity.Certainly, thermoplastic layer can comprise substantially inelastic polymer, as traditional polyolefin, as polyethylene (Low Density Polyethylene (" LDPE "), the linear low density polyethylene (" LLDPE ") etc. of Ziegler-Natta catalysis), polypropylene, polybutene etc.; Politef; Polyester, as polyethylene terephthalate etc.; Polyvinyl acetate; Polyvinyl chloride-acetate; Polyvinyl butyral resin; Acrylic resin, as polyacrylate, polymethyl acrylate, polymethyl methacrylate etc.; Polyamide, as nylon; Polrvinyl chloride; Poly-inclined vinylidene chloride; Polystyrene; Polyvinyl alcohol; Polyurethane; Poly-lactic acid; Their copolymer and mixture etc.In certain embodiments, employ polyolefin (as traditional and/or plastic body) and occupy about 55 % by weight of the polymer content of the thermoplastic compounds forming thermoplastic layer or more, in some embodiments, for about 60 % by weight or more, and be in some embodiments, about 65 % by weight to 100 % by weight.
The thickness of thermoplastic layer and elastic layer is normally by the balance suitable between film elasticity and intensity with realization selected.Such as, the thickness of elastic layer is typically about 20 to about 200 microns, in some embodiments, is about 25 to about 175 microns, and in some embodiments, is about 30 to about 150 microns.Elastic layer also can account for about 70% of the gross thickness of film to about 99.5%, in some embodiments, accounts for about 80% of the gross thickness of film to about 99%.On the other hand, the thickness of thermoplastic layer is typically about 0.5 to about 20 microns, in some embodiments, is about 1 to about 15 microns, and in some embodiments, is about 2 to about 12 microns.Thermoplastic layer also can account for about 0.5% of the gross thickness of film to about 30%, and in some embodiments, accounts for about 1% of the gross thickness of film to about 20%.The gross thickness of film is about 20 to about 250 microns, in some embodiments, is about 25 to about 225 microns, and in some embodiments, is about 30 to about 200 microns.
Regardless of specific film component, film and/or the material for the formation of film can also through one or more extra procedure of processings.In one embodiment, such as, for the elastomer polymer in film with non-woven lining surface layer pressure before, afterwards and/or period occur crosslinked, to give film stronger elastic characteristic.By polymer is carried out electromagnetic radiation with induced cross-linking, as ultraviolet light, electron beam irradiation, nature and artificial radioisotope's (as α, β and gamma-rays), X-ray, neutron beam, positron beam, laser beam etc.The wavelength (" λ ") of electromagnetic radiation is about 1000 nanometers or less, in some embodiments, is about 100 nanometers or less, and in some embodiments, is about 1 nanometer or less.Electron beam irradiation, such as, have about 1 nanometer or less wavelength usually.Similarly, the total amount (in one or more steps) used can be that about 1 Megarad (Mrad) is to about 30 Megarads, in some embodiments, for about 3 Megarads are to about 25 Megarads, and in some embodiments, for about 5 to about 15 Megarads.In addition, energy level can be that about 0.05 million-electron-volt (MeV) is to about 600MeV.By crosslinked, three-dimensional crosslinked network can be formed, to give the extra elasticity in material machine direction, transverse machine or both direction.
III. other facings
If desired, composite of the present invention can also comprise the known facings of other prior art, as nonwoven web material, film, foam etc.Such as, this composite can comprise extra nonwoven facings, as melt spray fibre web, spunbond fibre web, bonded carded web, wet laid web (wetlaidweb), air-flow method fibre web, with formed web etc., and above-mentioned combination.In a specific embodiment, extra facings is bonded carded facings.In bonded carded facings, any fiber of wishing length can be used, as short fiber, continuous fiber etc.Such as, the fibre length of spendable short fiber is about 1 to about 150 millimeters, in some embodiments, for about 5 to about 50 millimeters, in some embodiments, be about 10 to about 40 millimeters, and in some embodiments, be about 10 to about 25 millimeters.Such fiber can make carded web by the fiber of packing is separated into fiber by picker.Then, by fiber by combing or carding apparatus transmission, further defibre is also arranged in a machine direction to form the nonwoven web of the fiber of machine direction location.Subsequently, mode as above for carded web can be bonded easily.
Although do not require, extra facings may also be lightweight and low intensive.Such as, the basic weight of facings is about 1 to about 45 grams/m, in some embodiments, is about 2 to about 30 grams/m, and in some embodiments, is about 3 to about 20 grams/m.The peak load of facings in transverse machine (" CD ") is about 350 gram forces/inch (width) or less, in some embodiments, for about 300 gram forces/inch or less, in some embodiments, for about 50 to about 300 gram forces/inch, in some embodiments, for about 60 to about 250 gram forces/inch, and in some embodiments, for about 75 to about 200 gram forces/inch.If desired, nonwoven web facings also has low-intensity in machine direction (" MD "), if the peak load in machine direction is about 3000 gram forces/inch (width) or less, in some embodiments, for about 2500 gram forces/inch or less, in some embodiments, for about 50 to about 2000 gram forces/inch, and in some embodiments, for about 100 to about 1500 gram forces/inch.
As mentioned above, with rete pressure of the present invention before, also extra nonwoven facings is stretched in machine direction and/or transverse machine, and experiences other known procedure of processing, as perforation, heat treatment etc.
IV. lamination
In order to strengthen persistency and the stability of the composite obtained, usually by directly elastic composition being extruded on the surface of nonwoven facings, by film and facings laminated together.This makes to have between elastic composition and the fiber of nonwoven facings to contact largely, also improves the ability that meltblown fibers is bonded to elastic composition further.Like this, what can use in without the need to traditional stack adhesion technique has enough degree of adhesions by when damaging large calorimetric and the pressure of low intensive nonwoven web facings.If needed, promote lamination, as binding agent, suction etc. by various method.In one embodiment, such as, during lamination by means of suction by film to facings bias voltage.
No matter use which kind of laminating method, select suitable tack temperature by contribute to the elastomer polymer of film melting and/softening, it can be flowed and be melt into nonwoven facings, thus forming overall film/nonwoven composites.In addition, because elastomer polymer can physically be absorbed in and adhere to fiber on bonding position, enough binding formings can be realized without the need to the substantially softening polymer being used for being formed facings.Certainly, should be understood that, in certain embodiments, the temperature of nonwoven facings can higher than its softening point.In order to realize the binding forming of the hope between film and nonwoven facings, the temperature of the elastic composition extruded is typically about 50 DEG C to about 300 DEG C, in some embodiments, is about 60 DEG C to about 275 DEG C, and in some embodiments, be about 70 DEG C to about 260 DEG C.
Now in detail the various embodiments of lamination of the present invention will be described.With reference to Fig. 1, such as, show the embodiment being formed the method for composite by elastica and melt-blown facings.In this embodiment, melt-blown facings 30 is on line formed by with under type: be fed to extruder 8 from hopper 6 by raw material (as polypropylene), and the compositions extruded be provided in meltblown beam 9 subsequently.When polymer leaves die head 9 by aperture (not shown), high-pressure fluid (as, the air of heating) polymer flow will be made to attenuate and be dispersed into microfibre 11, to form melt-blown facings 30 on the surface that described microfibre 11 is randomly deposited in roller 70.Should be understood that, melt-blown facings 30 can also be formed in the orifice surface (as line, band, fabric etc.) of separation, be horizontally through roller 70 subsequently.In addition, should be understood that, melt-blown facings 30 also can be disperseed by feed rolls simply, and without the need to being formed on line.
In the embodiment shown in figure 1, yet forms both the elastica comprising single thermoplastic layer 23 and single elastic layer 21.More specifically, the raw material of elastic layer 21 can be added to the hopper 12 of extruder 14, and the raw material of thermoplastic layer 23 can be added to the hopper 22 of extruder 24.Material at high temperature mixes dispersedly and compound in extruder 14 and 24.Such as, in extruder 14, the melt blending of elastic composition can occur in about 50 DEG C to 300 DEG C, in some embodiments, is about 60 DEG C to about 275 DEG C, and in some embodiments, is about 70 DEG C to about 260 DEG C.The melt blending of thermoplastic compounds can occur in extruder 24, and its temperature is identical with the temperature of the elastic composition of use, lower or higher.Such as, the melt blending of thermoplastic compounds can occur in the temperature of about 50 DEG C to about 250 DEG C, in some embodiments, is about 60 DEG C to about 225 DEG C, and in some embodiments, is about 70 DEG C to about 200 DEG C.During melt blending, apparent shear rate can be about 100 seconds -1to about 10,000 second -1, in some embodiments, be about 500 seconds -1to about 5000 seconds -1, and in some embodiments, be about 800 seconds -1to about 1200 seconds -1.This apparent shear rate equals 4Q/ π R 3, the volume flow rate (" m of to be wherein Q be polymer melt 3/ s "), R are the diameter (" m ") of the capillary tube (as extruder die head) that molten polymer flows through.
By any known technology, the material of compound can be formed film, described technology comprises curtain coating, flat-mould head extrusion molding etc.In the specific embodiment of Fig. 1, such as, elasticity and thermoplastic layer are by " curtain coating " in melt-blown facings 30, and as is known in the art, this facings 30 is positioned on roller 70.Therefore, facings 30 defines the elastica 40 of curtain coating, make elastic layer 21 directly adjacent with facings 30.In order to the combination between reinforcing membrane 40 and facings 30, apply suction force with the upper surface making film 40 be biased toward melt-blown facings 30.This can come in (as vacuum tank, guide plate (shoes), roller etc.) and each position in composite forming technology in various ways.In the embodiment shown in figure 1, such as, the roller 70 of casting films 40 is the vacuum furnaces that can apply the suction force of wishing thereon.Can when significantly not destroying the integrity of low-intensity facings the amount of selectivity control and suck power to strengthen combination.Such as, gas vacuum pressure can be used to apply suction force, described suction force is about 0.25 kPa or larger, in some embodiments, is about 0.3 to about 5 kPas, and in some embodiments, is about 0.5 to about 2 kPas.Such vacuum aided laminating can when without the need to use in calendered layer platen press normally used may damage large calorimetric and the pressure of nonwoven facings globality form the composite of high strength.In fact, if really wished, the roller 70 forming film 40 thereon even can keep at ambient temperature.
Although do not need to illustrate, the second facings 31 can also be laminated to elastica 40.The second layer 31 that can be formed on line or be produced by feed rolls (such as, roller 62).Second facings 31 can be non-woven lining face, and the nonwoven web material, film, foam etc. of other type.When lamination, elastica 40 is merged to melting to facings 30 and 31 to form composite 80 on a large amount of separating and combining position.That is, elastomeric polymer that is softening and/or molten film 40 makes them can physically be absorbed in the fiber of material 30 and 31.Elastica 40 can have certain viscosity and make it also adhere to fiber when lamination.If desired, carry out under bonding can occur in the temperature being not enough to the polymer softening facings 30 and 31 substantially, they are not merged to melting substantially each other.By such mode, the composite 80 obtained can keep nonwoven facings physical property (such as, liquid permeable, pliability, volume and feel) preferably.
Without departing from the spirit and scope of the present invention, the extra processing that various prior art also can be adopted known and/or modification step, as cutting, stretching etc.Such as, optionally mechanical stretching composite in transverse machine and/or machine direction, to improve ductility.In the embodiment shown in figure 1, such as, on CD and/or MD direction, increase progressively elastomeric compositions by means of two or more the roller 90 reeded of tool on CD and/or MD direction and carry out machining composite material.? the people such as Rhimno. 2004/0110442 U.S. Patent application and the people such as Gerndtno. 2006/0151914 U.S. Patent application in describe the structure of side roll (the Groovedsatelliteroll)/backing roll of trough of belt, these entirety are incorporated herein by reference for all objects at this.Grooved roller 90 can be made up of steel or other hard material (as hard rubber).
Fig. 4-5 also show the mode that grooved roller can increase progressively elastomeric compositions.As shown in the figure, such as, side roll (satelliteroll) 382 can engage with backing roll 384, and any one in them includes multiple ridge (ridge) 383, and described ridge defines the multiple grooves 385 intersected with the grooved roller in transverse machine.Groove 385 is usually directionally perpendicular with the direction of material extending.In other words, groove 385 is orientated machine direction with elastomeric compositions in the cross machine direction.Similarly, groove 385 is also in the cross machine direction orientable, with elastomeric compositions in a machine direction.The ridge 383 of side roll 382 intermeshes with the groove 385 of backing roll 384, and the ridge 383 of the groove 385 of side roll 382 and backing roll 384 intermeshes.
The size of groove 385 and ridge 383 and parameter all have extreme influence to the ductility brought by roller 382 and 384.Such as, the quantity of the groove 385 that roller is equipped with is typically about 3 to 15 grooves per inch, in some embodiments, is about 5 to 12 grooves per inch, and in some embodiments, is about 5 to 10 grooves per inch.Groove 385 can also have the specific degree of depth " D ", is typically about 0.25 to about 1.0 centimetres, and in some embodiments, is about 0.4 to about 0.6 centimetre.In addition, the distance " P " at the peak between groove 385 and peak is typically about 0.1 to about 0.9 centimetre, and in some embodiments, is about 0.2 to about 0.5 centimetre.And grooved roller engagement distance " E " between groove 385 and ridge 383 can be about 0.05 to about 0.8 centimetre, in some embodiments, is about 0.1 to about 0.7 centimetre, and in some embodiments, is about 0.15 to about 0.6 centimetre.In any case, in one or more directions composite 80 (Fig. 1) can be stretched as the size (as length or width) of about 100% to about 750% of its front original dimension that stretches, in some embodiments, for about 125% to about 500%, and be in some embodiments, about 150% to about 400%.If desired, before enforcement increases progressively extension or period, also heat composite, make it lax a little and be easy to extend.Any suitable method well known in the prior art can be utilized to heat, the nip rolls of such as hot-air, infrared heater, heating or by one or more warm-up mill or vapor can partly embracing layer laminate etc.Grooved roller itself can also be heated.Should be understood that, the layout of other grooved roller is also same being applicable to, as two grooved rollers are tightly adjacent each other.
Except above-mentioned grooved roller, other technology also can be used to carry out in one or more directions mechanically elastomeric compositions.Such as, composite can through being used for the tenter frame of elastomeric compositions.Such tenter frame is that prior art is known, such as, the people such as Mormanno. 2004/0121687 U.S. Patent application in existing to describe.Can also constriction composite.? mormanthe 5th, 336, No. 545, the 5th, 226, No. 992, the 4th, 981, No. 747 and the 4th, 965, No. 122 United States Patent (USP)s and the people such as Mormanno. 2004/0121687 U.S. Patent Application Publication in describe applicable constriction technology, above-mentioned entirety is incorporated herein by reference for all objects at this.
Referring again to Fig. 1, when formed, composite 80 can be cut, be wound around and be stored on takers-in 95.Composite 80 before being wound on takers-in 95 and/or period can occur in a machine direction retraction.This realizes by utilizing the roller 95 of less linear velocity.Alternatively, composite 80 can be wound on roller 95 when straining.
In the embodiment shown in figure 1, and as mentioned above, the elastic layer of film is placed between nonwoven facings and the thermoplastic layer of film.But in such embodiments, thermoplastic layer keeps exposed state, and damaged in technique subsequently, as when with grooved roller on CD and/or MD direction during elastomeric compositions.In some cases, damage can arrive the degree that thermoplastic layer cannot give the intensity that composite is wanted.Therefore, in order to such damage be minimized, one or more extra elastic layer can be adopted, thermoplastic layer be positioned between at least two elastic layers, and thus be protected during processing.
Again referring to Fig. 2, such as, show the embodiment being formed the method for composite by elastica, this film comprises two thermoplastic layers between two elastic layers.In this embodiment, nonwoven facings 130 is formed on line by following steps, is fed to extruder 108, the compositions extruded is provided to raw material in meltblown beam 109 subsequently from hopper 106.To form melt-blown facings 130 on the surface that microfibre 111 is randomly deposited in roller 170.The raw material of the first elastic layer 121 is added in the hopper 112 of extruder 114, and the raw material of the first thermoplastic layer 123 is added in the hopper 122 of extruder 124.Material is coextruded to and is positioned at nonwoven facings 130 on roller 170 to form the first film precursor 241.Similarly, the raw material of the second elastic layer 221 is added in the hopper 212 of extruder 214, and the raw material of the second thermoplastic layer 223 is added in the hopper 222 of extruder 224.Subsequently material is coextruded to without to be wrapped on grooved roller 162 but to be positioned in the nonwoven facings 131 on the second roller 270 to form the second film precursor 242.
As mentioned above, suction force can be applied the first film precursor 241 is biased toward the upper surface of nonwoven facings 130 to form the first composite material precursors 310.Similarly, suction force can also be applied on the second film precursor 242, form the second composite material precursors 320 with the upper surface being biased toward nonwoven facings 131.In the embodiment shown in Fig. 2, composite material precursors 310 and 320 subsequently through the grooved roller 190 being used for stretching on CD and/or MD direction to form single composite 180, it comprises the film formed by the film precursor 241 and 242 be separated.Certainly, except forming film as shown in Figure 2 and forming composite by the film precursor of the separation gathered together subsequently, will also be understood that and can also use other method.Such as, as known in the art, film can be formed simply by by the surface dividing other compositions to be coextruded to roller.
Regardless of the concrete grammar formed, the present inventor finds, and the composite obtained all has ductility and the elastic recovery of height.Namely, composite in the cross machine direction, in machine direction or the percentage elongation (" peak elongation ") this both direction with peak load be about 75% or larger, in some embodiments, for about 100% or larger, and be in some embodiments, about 150% to about 500%.This composite is also elastic, because extended when applying tensile force at least one direction, and when discharging tensile force, being shunk/getting back to close to its original size.Such as, the material of drawn has the tensile elongation of length unstretched when loosening than it large at least 50%, and when discharging tensile force, it will reply at least 50% of its tensile elongation.The example of a hypothesis is: the long material sample of one (1) inch is stretched at least 1.50 inches, and when release tensile force, will be returned to the length no longer than 1.25 inches.Ideally, composite shrink or recovery stretch length at least 50%, even more preferably, at least 80%.
Composite also has the high strength in machine direction and/or transverse machine.Such as, the CD peak load of composite is at least about 1000 gram forces/inch (" g f/ in "), in some embodiments, for about 1100 to about 3000g f/ in, and in some embodiments, for about 1200 to about 2500g f/ in.Similarly, MD peak load is at least about 1500 gram forces/inch (" g f/ in "), in some embodiments, for about 1500 to about 6000g f/ in, and in some embodiments, for about 2000 to about 5000g f/ in.
V. goods
Composite of the present invention can be widely used in various application.As mentioned above, such as, this composite can be used for absorbing products." absorbing products " is commonly referred to as any goods that can absorb water or other fluid.The example of some absorbing products includes, but not limited to personal-care supplies, as diaper, training pants, absorption underpants, incontinence article, women sanitary articles (as sanitary towel), swimming suit, baby wipe towel etc.; Medical absorbent products is as clothing, windowing material, heelpiece, mattress, binder, absorption curtain and medically wipe towel; And napkin, clothing articles etc.The materials and methods being applicable to be formed such absorbing products is well known by persons skilled in the art.Usually, absorbing products comprises the layer (as skin) of basic impermeable liquid, the layer (as side liner, layer etc. of gushing out) of liquid permeable and absorbent cores.In a specific embodiment, composite of the present invention can be used for providing elastic waist belt, lower limb cover/filler, stretchable lug (stretchableear), side panel maybe can to stretch the purposes of outer housing.
Now in detail the various embodiments of the absorbing products that can be formed according to the present invention will be described.With reference to Fig. 3, such as, show an embodiment of disposable diaper 450, it generally defines front waist portion 455, back waist portion 460 and is interconnected the mid portion 465 of front and rear waist portions.Front waist portion 455 and back waist portion 460 comprise the regular section that structure extends to the diaper of the front and rear abdomen area of wearer during use respectively substantially.The mid portion 465 of diaper comprises the regular section that structure is stretched across the diaper of the crotch area between wearer lower limb.Thus, mid portion 465 usually repeats the region that liquid gushes out in diaper.
In non-limiting manner, diaper 450 comprises outer housing or bottom 470, with bottom 470 in the face of the side liner of liquid permeable of arranging or top layer 475 and absorbent cores main body or liquid retention structure 480, as absorption pad, between bottom 470 and top layer 475.Bottom 470 defines length or longitudinal direction 486 and width or horizontal direction 485, in the shown embodiment, their length with diaper 450 and width consistent.Liquid retention structure 480 usually has respectively than the length of bottom 470 and the short length of width and width.Therefore, the marginal portion of diaper 450, as the edge of bottom 470, can extend across the end limit of liquid retention structure 480.In the shown embodiment, such as bottom 470 extends the terminal edge region of liquid retention structure 480 to form side and the end limit of diaper 450.Top layer 475 usually and bottom 470 together extend, but as desired, optionally cover the region more greater or lesser than the area of bottom 470.
In order to improve fit-state and contribute to reducing body fluid situation about spilling from diaper 450, as explained further below, diaper side and end limit can make it to have elasticity with suitable elastic part.Such as, typically as shown in Figure 3, diaper 450 can comprise leg elastic 490, constructs with the side can straining diaper 450 to obtain elastic leg band, this elastic leg band can closely be fitted around wearer leg, reduces and leaks and obtain better comfort and outward appearance.Waist elastics 495 is used for making the end limit of diaper 450 to have elasticity, provides elastic belt.Waist elastics 495 structure provides the degree of fitting tightly that wearer section is springy, comfortable.Elastic composite of the present invention is suitable for and makes leg elastic 490 and waist elastics 495.Exemplary such material is laminate, comprises or adheres to bottom, makes to apply elastic constrictive forces to bottom 470.
As everyone knows, secure component, as hook or latch closure, can be used to diaper 450 to be fixed on it wearer.Alternatively, also can use other secure component, as button, pin, buckle, the securing member etc. of tape fastener, binding agent, fabric and ring.In the shown embodiment, diaper 450 comprises a pair side panel 400 (or lug) be combined on securing member 402, shown by the hook portion of hook and latch closure.Usually, side panel 400 is combined on the side of the diaper of in waist portions 455,460, and laterally stretches out.Side panel 400 has elasticity owing to employing elastic composite of the present invention or otherwise has elasticity.? roesslerw095/16425 PCT patent application, the people such as Roessler5th, 399, No. 219 United States Patent (USP)s, fries-the 5th, 540, No. 796 United States Patent (USP)s and the 5th, 595, No. 618 friesunited States Patent (USP) in describe the example of absorbing products of the securing member mark comprising elastic side panels and selectivity structure, these entirety are incorporated herein by reference for all objects at this.
Diaper 450 can also comprise key-course 405 of gushing out, between top layer 475 and liquid retention structure 480, promptly to receive liquid secretions and liquid secretion thing to be distributed to the liquid retention structure 480 in diaper 450.Diaper 450 can also comprise air-permeable layer (not shown), also referred to as spacer or wall, bottom 470 and liquid retention structure 480 to be separated the dampness that the outer surface that reduces breathable outer housing or bottom 470 bring medicated clothing between liquid retention structure 480 and bottom 470.? bishopthe 5th, 486, No. 166 United States Patent (USP)s and ellisthe 5th, 490, No. 846 United States Patent (USP)s in describe the example of applicable key-course 305 of gushing out.
As Fig. 3 representativeness illustrates, disposable diaper 450 also comprises a pair accommodation flap (containmentflap) 410, and structure provides obstacle to the body secretion fluid of horizontal mobility.Holding flap 410 can along the horizontal relative side of diaper, and adjacent with the side of liquid retention structure 480.Each accommodation flap 410 generally defines and does not adhere to limit, and it is configured to the uprightly vertical configuration maintained at least mid portion 465 of diaper 450, to form the seal with wearer's body.Hold flap 410 also along the whole length longitudinal extension of liquid retention structure 480, or can only to extend along the length thereof of liquid retention structure.When hold flap 410 than liquid retention structure 480 length in short-term, hold flap 410 and be optionally arranged in the optional position of the side of the diaper 450 along mid portion 465.Such accommodation flap 410 is known for a person skilled in the art.Such as, exist enloethe 4th, 704, No. 116 United States Patent (USP)s in describe applicable accommodation flap 410 knot make and arrange.
Diaper 450 can be various applicable shapes.Such as, diaper can be whole rectangle, T-shaped or the shape close to water clock.In the shown embodiment, diaper 450 is generally I shape.Other parts be applicable to that can be added to absorbing products of the present invention can comprise and well known to a person skilled in the art waist flap etc.? the people such as Meyerthe 4th, 798, No. 603, bernardinthe 5th, 176, No. 668, the 5th, 176, No. 672 the people such as Bruemmer, proxmire deng peoplethe 5th, 192, No. 606 and the people such as Hansonthe 5th, 509, describe the example being applicable to the diaper structure together used with elastic composite of the present invention in No. 915 United States Patent (USP)s, these diapers can also comprise other parts that can be used for diaper, are incorporated herein by reference by these entirety for all objects at this.
Any known connection mechanism can be adopted by the various region of diaper 450 and/or assembling parts to together, as binding agent combination, combination of ultrasound, hot sticky combination etc.The binding agent be applicable to comprises such as hot-melt adhesive, pressure sensitive adhesives etc.When using binding agent, binding agent can use the pattern of uniformly layer, figuratum layer, injection or arbitrary line, whirlpool or the point be separated.In the shown embodiment, such as, top layer 475 and bottom 470 can be bonded to each other with the bonding agent of wire, and combine with liquid retention structure 480, and binding agent is as hot-melt adhesive, pressure sensitive adhesives.Similarly, other diaper component, as elastic parts 490 and 495, fastening assembly 402 and layer 405 of gushing out all can utilize above-mentioned connection mechanism to be assembled on goods.
Although be described above the various configurations of diaper, should be understood that, the configuration of other diaper and absorbing products also falls into scope of the present invention.In addition, the present invention is not limited to diaper.In fact, exist the people such as DiPalmathe 5th, 649, No. 916 United States Patent (USP)s, kielpikowskithe 6th, 110, No. 158 and the people such as Blanevthe 6th, 663, No. 611 in describe the example of various absorbing products, these entirety are incorporated herein by reference for all objects at this.In addition, other example that can be incorporated to the personal-care supplies of this type of material is training pants (as side panel material) and women sanitary articles.Only exemplary mode, fletcher deng peoplethe 6th, 761, No. 711, the people such as VanGompelthe 4th, 940, No. 464, brandon deng peoplethe 5th, 766, No. 389 and the people such as Olsonthe 6th, 645, No. 190 various materials and methods U.S. patents disclosing the training pants that is suitable for together using with the present invention and construct training pants, these entirety are incorporated herein by reference for all objects at this.
Referring to following examples, the present invention will be easier to understand.
detection method
Tensile property:
The basic tensile strength values measuring bar according to ASTM standard D-5034.Particularly, sample is cut into or is otherwise provided as the size of 1 inch of (25.4 millimeters) (width) × 6 inch (152.4 millimeters) (length).Use the stretching detector of constant-rate-of-extension.Stretching detection system is Sintch stretching detector, can obtain from the MTSCorp. of EdenPrairie, Minnesota.Pulling force detector is equipped with the TESTWORKS4.08B software purchased from MTS company, to detect.Select suitable load bearing element, detected value is carried falling into fullcharging in the scope of the 10-90% of scale.Before being fixed on by sample and the back side is between the clip of 1 inch (25.4 millimeters) × 3 inches (76 millimeters).Clip surfaces through rubbery process, the size that clip is longer and direction of pull perpendicular.The pressure of clip remains the pressure of 60 to 80 pounds/square inch under air effect.Pull force calculation by the speed of 20 inch per minute clocks, the gauge length of 4 inches and 40% fracture-sensitive degree run.Detect three samples along machine direction (" MD "), detect three samples along transverse machine (" CD ").In addition, ultimate tensile strength (" peak load ") and peak elongation is also recorded.
Be stretched to stopping
The TESTWORKS4.08b software Sintech that (MTSCorp. of EdenPrairie, Minnesota) has RenewMTSmongoosebox (controller) is utilized to test.As described below, measure the percentage elongation percentage ratio of the material of load 2000 gram force." bar percentage elongation detection method " in the description of basic foundation ASTMD5035-95 is utilized to carry out such mensuration.Detect use two clamps, each clamp has two jaws, and each jaw has and sample contacts section.Material is fixed at grade by clamp, and outwards extends with specific speed.To select in transverse machine the sample size of in 3 inches and machine direction 7 inches.Clip size is width 3 inches, uses intermeshing clip, makes material can not landing between detection period.Clip separates 4 inches.Be loaded into sample, make the machine direction of sample be positioned at vertical direction.Prestrain close to 5-10 gram force is set.With the crosshead velocity measuring sample of 20 inch per minute clocks.Until remove sample when creating the stretching of 2000 gram forces, and stop subsequently detecting.Detection when the stretching of generation 2000 gram force is designated as percentage elongation %.The result obtained is the meansigma methods of three kinds of samples, and gives the testing result of sample in transverse machine (CD) and/or machine direction (MD).
Hysteresis
Using is equipped with the Sintech1/S equipment of TESTWORKS software to measure the hysteresis of elastomeric material.Elastomeric material is cut into bar, the width of each bar is 3 inches, length is 6 inches.The two ends of material are clipped in the relative jaw of equipment, make the length at each 1 inch of material two ends remain in jaw, and the length of 4 inches can be used for stretching.By the bar of each material of rate tensile of 20 inch per minute clocks to the specific stretch value in tables of data, measure area under a curve (representing power × displacement), be recited as " load energy ".Subsequently, material bar is made to return back to length when tensile force is 0.During bouncing back, again measure area under a curve and record.This is " unloading energy ".Hysteresis is calculated according to following equation:
embodiment 1
This example demonstrates the ability forming elastic composite.The film used in composite comprises the elastic composition of 90 % by weight and the thermoplastic compounds of 10 % by weight.Elastic composition comprises the KRATON of 86 % by weight mD6716 (KratonPolymers, the LLC of Houston, Texas), 10 % by weight STYRON tMthe StandridgeColorCorporation (" SCC ") 4837 of 666D (DowChemical) and 4 % by weight.KRATON mD6716 comprises styrene-ethylene-butylene-styrene (" SEBS ") block copolymer, viscosifier and Tissuemat E close to 75 % by weight, and has the target melt flow rate (200 DEG C, 5kg) of 7g/10min.STYRON tMthe polystyrene resin of 666D to be melt flow rate (MFR) be 8g/10min (200 DEG C, 5kg).SCC4837 is the pigment comprising the titanium dioxide mixed with polyethylene.The thermoplastic compounds of film comprises the SCC4837 of the PP3155 (ExxonMobil) of 59.5%, the DOWLEXTM2517 (DowChemical) and 4 % by weight of 31.5 % by weight.PP3155 is melt flow rate (MFR) be 36g/10min (230 DEG C, 2.16kg) and density is 0.9g/cm 3homopolymer of polypropylene.DOWLEX tM2517 is melt index is 25g/10min (190 DEG C, 2.16kg), density is 0.917g/cm 3with the linear low density polyethylene resin that fusing point is 255 ℉.
Composite also comprises two facingss that film is clipped in the middle.A facings is the 17gsmT-133 polypropylene bonded carded web of the FiberVisions purchased from Georgia State Covington, and its directed ratio in machine direction and transverse machine is 5: 1.Bonded carded web peak load is in a machine direction about 1133 gram forces/inch, and peak load is in the cross machine direction about 150 gram forces/inch.Another facings is by the METOCENE of 60 % by weight tMthe %VISTAMAXX of MF650W (LyondellBasell) and 40 weight tMthe melt spray fibre web of the 17gsm that 2330 (ExxonMobil) are formed.METOCENE tMmF650W is melt flow rate (MFR) be 500g/10min and density is 0.88g/cm 3to 0.92g/cm 3the polypropylene homopolymer of metallocene catalysis.VISTAMAXX tM2330 is melt flow rate (MFR)s be 285g/10min and density is 0.868g/cm 3polyolefin copolymer/elastomer.Melt spray fibre web peak load is in the cross machine direction about 273 gram forces/inch.
By taking the bead of the various polymer of proper proportion, their mixing are loaded in container, and by stirring, they are mixed, thus by the polymer compound of film and meltblown layer.After compound, utilizing 20 " die head of wide Randcastle co-extruded films makes the elastomer film that basic weight is 32gsm.The elastomeric component of film enters extruder with the rotary pump speed of 7.96rpm, and flexible pipe and die head temperature are about 500 ℉.The thermoplastic component of film is with the speed of 10.35rpm and enter extruder at the flexible pipe temperature of about 380 ℉.In this case, thermoplastic layer is extruded and is positioned at center membrane, and elastomer portion is extruded, and is positioned on any side of thermoplastic layer, forms sandwich structure (i.e. A-B-A film, its middle level B is thermoplastic body, and layer A is elastomer).Utilizing 20 " wide melt-blown systems makes through succession of steps the melt spray fibre web that basic weight is 17gsm; the per inch die width of this system has 30 capillaries; air pressure is 4.5psi; rotary pump speed is 17.3rpm; die head height is 10.5 inches; air themperature is about 630 ℉, and die head temperature is 480 ℉.Bonded carded web is supplied by roller, and enters in composite formation process without winding.
In order to form composite, in translational speed be 63 feet per minute clocks formation line on form melt spray fibre web.Subsequently film is extruded on melt spray fibre web, and when melting during film is applied to take out suction force and extruding.Vacuuming operation adopts 1 " H 2o-15 " H 2the vacuum pressure of O.Subsequently when film is still in molten condition, heat bonding carded web is extruded on film/meltblown layer.Then, composite is delivered to have engagement with per inch be the roll unit of 5 grooves of 0.252 inch.Then winding material.Table 1 shows the material character of this material obtained.Similarly, Fig. 6 and 7 shows the scanning electron microscope image that display is positioned at the rete cross section of the thermoplastic composition at center.
Table 1 material character
embodiment 2
This example demonstrates the ability forming elastic composite.The film used in composite comprises the elastic composition of about 90-95 % by weight and the thermoplastic compounds of 5-10 % by weight.Elastic composition comprises the KRATON of 86 % by weight the %STYRON of MD6716,10 weight tMthe SCC4837 of 666D and 4 % by weight.Thermoplastic compounds comprises the PP3155 of 48 % by weight, the DOWLEX of 48 % by weight tMthe SCC4837 of 2517 and 4 % by weight.This composite also comprises two facingss that film is clipped in the middle.Two facingss of composite are by the VALTEC comprising 60 % by weight tMhH441 (LyondellBasell) and VISTAMAXX tMthe melt spray fibre web of the 17gsm of 2330 is made.VALTEC tMhH441 is melt flow index be 440g/10min (230 DEG C, 2.16kg) and density is 0.902g/cm 3the homopolymer of polypropylene of superelevation melt flows.
By taking the bead of the various polymer of proper proportion, their mixing are loaded in container, and by stirring, they are mixed, thus by the polymer compound of film and meltblown layer.After compound, utilizing 20 " wide Randcastle co-extruded films die head makes the elastomer film that basic weight is 45gsm.The elastomeric component of film enters extruder with the die head temperature of the flexible pipe temperature of the rotary pump speed of 8.96rpm, 500 ℉ and 480 ℉.The thermoplastic component of film is to enter extruder with the flexible pipe temperature of the speed of 10.35rpm and 380 ℉.In this case, the elastomeric component of film is extruded, and is positioned at center membrane, and thermoplastic component is extruded, and is positioned at any side of elastic layer to form sandwich structure (i.e. A-B-A film, its middle level A is thermoplastic body, and layer B is elastomer).Utilizing 20 " wide melt-blown systems prepares through succession of steps two melt-blown facingss that basic weight is 17gsm; and the per inch die width of this system has 30 capillaries, and rotary pump speed is 17.3rpm, and die head height is 10.5 inches; air themperature is 630 ℉, and die head temperature is 480 ℉.
In order to form composite, with the speed of 63 feet per minute clocks, melt-blown for bottom facings is placed on shaped wire without winding.Subsequently film is extruded on melt spray fibre web, and when melting, suction force is applied to film and extrude.Vacuuming operation adopts 1 " H 2o-15 " H 2the vacuum pressure of O.Subsequently when film is still in molten condition, another melt spray fibre web is extruded on film/meltblown layer.Then, composite is delivered to have engagement with per inch be the grooved roller unit of 5 grooves of 0.168 inch.Then winding material.Table 2 shows the material character of the acquisition of this material.
Table 2 material character
embodiment 3
Illustrate the ability forming elastic composite.The film that composite uses comprises the elastic composition of about 90-95 % by weight and the thermoplastic compounds of 5-10 % by weight.Elastic composition comprises 59.5 % by weight KRATON mD6716,31.5 % by weight STYRONTM666D and 4 % by weight SCC4837.Thermoplastic compounds comprises 59.5%PP3155,31.5 % by weight DOWLEX tM2517 and 4 % by weight SCC4837.This composite also comprises two facingss that film is clipped in the middle.This facings is identical with those use in embodiment 1.
By taking the bead of the suitable part of each polymer by the polymer compound of film and meltblown layer, by they combination loadings container, and by stirring, they are mixed.After compound, utilizing 20 " to form basic weight be the elastica of 44gsm for wide Randcastle co-extruded films die head.The elastomeric component of film is fed to that rotary pump speed is 7.96rpm, flexible pipe temperature is 500 ℉ and die head temperature is the extruder of 480 ℉.The extruder of the thermoplastic component of film is fed to speed to be 10.35rpm and flexible pipe temperature be 380 ℉.In this case, elastomer layer is extruded at center membrane, and thermoplastic component is extruded to any side of thermoplastic layer to form sandwich structure (i.e. A-B-A film, its middle level B is elastomer, and layer A is thermoplastic body).The comb of bonding is weaved cotton cloth and is provided on roller, without entering composite material forming step with being wound around.Utilizing 20 " wide melt-blown systems manufactures through succession of steps two melt-blown facingss that basic weight is 17gsm; and the per inch of the die width of this system has 30 capillary tubies; air pressure is 2psi; rotary pump speed is 17.3rpm; die head height is 10.5 inches; air themperature is 630 ℉, and die head temperature is 480 ℉.
In order to manufacture composite, in translational speed be 63 feet per minute clocks form wire on formed bottom melt-blown facings.Subsequently film is extruded on melt-blown nonwoven fibre web, and during still keeping melting, is applied in suction force and is expressed on film.With 1 " H 2o-15 " H 2the vacuum pressure of O obtains suction force.Subsequently when film is still in molten condition, another melt-blown nonwoven fibre web is extruded on film/meltblown layer.Then, composite is guided to per inch and there is the grooved roller unit that engagement is 5 grooves of 0.168 inch.Then winding material.What table 3 showed this material obtains material character.
Table 3 material character
embodiment 4
Illustrate the ability forming elastic composite.The film that composite uses comprises the elastic composition of 100 % by weight.Elastic composition comprises 86 % by weight KRATON mD6716,10 % by weight STYRONTM666D and 4 % by weight SCC4837.This composite also comprises two facingss that film is clipped in the middle.A facings is the bonded carded web of embodiment 1.Another facings is by 60 % by weight DNDA1082NT-7 (DOW Chemical) and 40 % by weight VISTAMAXX tMthe melt spray fibre web of 2330 17gsm formed.DNDA1082NT-7 is melt flow index is 155g/10min (190 DEG C, 2.16kg), density is 0.933g/cm 3with the linear low density polyethylene resin that fusing point is 257 ℉.
By taking the bead of the suitable part of each polymer by the polymer compound of film and meltblown layer, by they combination loadings container, and by stirring, they are mixed.After compound, utilizing 20 " wide Randcastle co-extruded films die head makes the elastica that basic weight is 46gsm.The elastomeric component of film is fed to that rotary pump speed is 7.96rpm, flexible pipe temperature is 500 ℉ and die head temperature is the extruder of 480 ℉.The comb of bonding is weaved cotton cloth and to be supplied by from roller, without entering in composite forming technology with being wound around.Utilizing 20 " wide melt-blown systems forms through succession of steps the melt-blown nonwoven fibre web that basic weight is 17gsm; and the per inch die width of this system has 30 capillary tubies; air pressure is 4.5psi; rotary pump speed is 17.3rpm; die head height is 10.5 inches; air themperature is 630 ℉, and die head temperature is 480 ℉.
In order to manufacture composite, in translational speed be 63 feet per minute clocks shaped wire on form melt spray fibre web.Subsequently film is extruded on melt spray fibre web, and during still keeping melting, is applied in suction force and is expressed on film.With 1 " H 2o-15 " H 2the vacuum pressure of O obtains suction force.Subsequently when film is still in molten condition, hot sticky comb is weaved cotton cloth and extrudes on film/meltblown layer.Then, composite is guided to per inch and there is the roll unit that engagement is 5 grooves of 0.224 inch.Then winding material.What table 4 showed this material obtains material character.
Table 4 material character
embodiment 5
Illustrate the ability forming elastic composite.Form film as described embodiments.This composite also comprises two facingss that film is clipped in the middle.Two facingss are all bonded carded web as described in Example 1.By taking the bead of the suitable part of each polymer by the polymer compound of film and meltblown layer, by they combination loadings container, and by stirring, they are mixed.After compound, utilizing 20 " to form basic weight be the elastica of 49gsm for wide Randcastle co-extruded films die head.The elastic component of film is supplied to that rotary pump speed is 8.96rpm, flexible pipe temperature is 500 ℉ and die head temperature is the extruder of 480 ℉.The extruder of the thermoplastic compounds of film is fed to rotary pump speed to be 10.35rpm and flexible pipe temperature be 380 ℉.In this case, elastomer layer is extruded at center membrane, and thermoplastic component is extruded to any to form sandwich structure (i.e. A-B-A film, its middle level B is elastomer, and layer A is thermoplastic body) of thermoplastic layer.Bonded carded web is supplied by from roller, without entering composite forming technology with being wound around.
In order to manufacture composite, in translational speed be 63 feet per minute clocks the line that becomes second nature on form bottom thermal adhesive carded web.Subsequently, film is extruded on melt-blown nonwoven fibre web, and during still keeping melting, is applied in suction force and is expressed on film.With 1 " H 2o-15 " H 2the vacuum pressure of O obtains suction force.Subsequently when film is still in molten condition, another heat bonding carded web is extruded on film/meltblown layer.Then, composite is guided to per inch and there is the roll unit that engagement is 5 grooves of 0.168 inch.Then winding material.Table 5 shows the material character that this material obtains.
Table 5 material character
Although described specific embodiment of the invention scheme in detail, it should be noted, those skilled in the art, by the understanding to foregoing teachings, can expect the amendment of these embodiments, change and equivalent way easily.Therefore, scope of the present invention should be considered to appended claim and the scope of equivalent way thereof.

Claims (24)

1. an elastic composite, described composite comprises:
Elastica, described elastica comprises elastic composition; With
Be close to elastica position and be laminated to the nonwoven facings of elastica, the basic weight of wherein said nonwoven facings is 45 grams/m or less, and described nonwoven facings peak load is in the cross machine direction 350 gram forces/inch or less;
Wherein said composite in a machine direction, in transverse machine or the peak elongation that this both direction shows be 75% or larger, also have wherein, described elastica is multilamellar, this multilayer film comprises two elastic layers and the thermoplastic layer between them, described elastic layer is formed by described elastic composition, and described thermoplastic layer is formed by thermoplastic compounds, place and be laminated on it for one in the contiguous described elastic layer of wherein said nonwoven facings.
2. elastic composite according to claim 1, wherein said nonwoven facings peak load is in a machine direction 3000 gram forces/inch or less.
3. elastic composite according to claim 1, wherein said composite in a machine direction, in transverse machine or the peak elongation that this both direction shows be 150% to 500%.
4. the elastic composite according to any one of the claims, wherein said nonwoven facings is formed by containing polyolefinic compositions.
5. elastic composite according to claim 1, wherein said elastic composition 55 % by weight or more component of polymer be made up of the elastomer that at least one is essentially amorphous.
6. elastic composite according to claim 5, wherein said elastomer comprises styrene-butadiene, styrene-isoprene, s-B-S, styrene-isoprene-phenylethene, styrene-(Ethylene/Butylene), styrene-(ethylene-propylene), styrene-(Ethylene/Butylene)-styrene, styrene-(ethylene-propylene)-styrene, styrene-(Ethylene/Butylene)-styrene-(Ethylene/Butylene), styrene-(ethylene-propylene)-styrene-(ethylene-propylene), styrene-ethylene-(ethylene-propylene)-styrene, or their combination.
7. elastic composite according to claim 1, wherein polyolefin account for the component of polymer of thermoplastic compounds 55 % by weight or more.
8. elastic composite according to claim 1, wherein said elastic layer has the thickness of 20 microns to 200 microns separately, and described thermoplastic layer has the thickness of 0.5 micron to 20 microns.
9. elastic composite according to claim 1, wherein said nonwoven facings is melt-blown facings.
10. elastic composite according to claim 1, wherein said elastica is between nonwoven facings and other nonwoven facings.
11. 1 kinds of absorbent articles, described absorbent article comprises elastic composite according to claim 1.
12. 1 kinds of methods forming composite, described method comprises:
To form elastica on surface elastic composition being directly extruded into nonwoven facings, the basic weight of wherein said nonwoven facings is 45 grams/m or less, and described nonwoven facings peak load is in the cross machine direction 350 gram forces/inch or less;
Described elastica is made to be bonded to nonwoven facings to form composite, wherein said composite in a machine direction, in transverse machine or the peak elongation that this both direction shows be 75% or larger, also have wherein, the coextrusion together with thermoplastic compounds of described elastic composition, makes described elastica comprise two elastic layers and the thermoplastic layer between them.
13. methods according to claim 12, wherein said nonwoven facings is formed by containing polyolefinic compositions.
14. methods according to claim 12, described method also comprises applying suction force with the surface making elastica be partial to nonwoven facings.
15. methods according to claim 14, wherein use gas vacuum pressure to apply suction force.
16. methods according to claim 15, wherein said suction force is 0.3 to 5 kPa.
17. methods according to claim 12, described method also comprises in a machine direction, in transverse machine or this both direction extends composite, before wherein said composite is extended and extends to it original dimension 100% to 750% size.
18. methods according to claim 12, wherein said composite is by incrementally extending the grooved roller of composite in the cross machine direction.
19. methods according to claim 12, wherein said nonwoven facings is melt-blown facings.
20. methods according to claim 12, described method also comprises other non-woven lining surface layer is depressed into elastica, makes described elastica between described nonwoven facings and other nonwoven facings described.
21. elastic composites according to claim 1, the basic weight of wherein said nonwoven facings is 2 to 20 grams every square metre.
22. elastic composites according to claim 1, wherein said nonwoven facings peak load is in the cross machine direction 50 to 300 gram forces/inch.
23. methods according to claim 12, the basic weight of wherein said nonwoven facings is 2 to 20 grams every square metre.
24. methods according to claim 12, wherein said nonwoven facings peak load is in the cross machine direction 50 to 300 gram forces/inch.
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